I have also tried to think of a non welding fix for this problem but hadn't
progressed to a full solution. The only thing I don't like is bolts (and niuts)
in tension. If I can respectfully modify your mod kit, my suggestion would be
to use a saddle piece but with the bolts passing through it from front to back
through both tails of the strap. The bolts are then in shear.
With respect to removing the frame from the fuselage, the way to do it is to
apply a bit of leaverage to each of the four legs in turn, at the same time
heating the leg itself to soften the epoxy/metal bond. We used a hot air gun
with nozzle small enough to inject air into the tubes. Temperature required is
not much more than 150 or 200 degrees, I guess. Its only necessary to crack the
joint, it won't melt and rebond. Once all four legs are cracked off, the frame
can be persuaded to leave the aeroplane. The odd bit of flox might need to be
chipped off. The only thing we had to watch was that we didn't melt the
upholstery with hot air exiting the back of the tubes.
Graham
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